Checkweigher Weigh Time Optimization via Variable Evaluation
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Solution Overview
Problem
Existing weigh-in-motion systems sacrifice accuracy for speed, leading to unnecessary rejections due to limited weigh time and noise in weight data collection, especially when objects transition on and off the scale.
Innovation Solution
Implementing a variable object weighing evaluation point that allows weight data collection to begin as soon as an object transitions from the infeed conveyor and continues until it contacts the discharge conveyor, with the option to extend weigh time by adjusting the discharge conveyor elevation, thereby minimizing noise and increasing data collection duration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If weight data collection is performed for the entire object transition period on the scale, then weighing accuracy is improved, but weigh time is extended which may reduce throughput
Solution Approach 1:
The patent applies dynamics by making the weigh time adjustable rather than fixed. The system dynamically adapts the weighing duration based on actual object characteristics and scale conditions, allowing optimization between accuracy and throughput for each specific weighing event.
Solution Approach 2:
The patent changes the parameter of weigh time from a fixed value to a variable parameter that can be adjusted. By modifying this parameter based on object type, scale response characteristics, and operational requirements, the system achieves optimal balance between measurement precision and productivity.
2Measurement precision
If weigh platform length is increased to allow object settling, then signal noise is reduced and accuracy is improved, but device complexity and space requirements increase
Solution Approach 1:
The patent extracts the settling function from the physical weigh platform length and relocates it to the data processing stage. Instead of requiring a longer physical platform, the system uses signal filtering and averaging algorithms to eliminate noise and stabilize the weight reading, thereby achieving the same accuracy with simpler hardware.
Solution Approach 2:
The patent replaces the mechanical solution (longer weigh platform for physical settling) with an electronic/software solution (signal processing algorithms). By using digital filtering, moving averages, and noise reduction techniques, the system achieves signal stabilization without increasing mechanical complexity or platform dimensions.
3Productivity
If fixed evaluation point is used for weight determination, then processing speed is maintained, but unnecessary rejections occur due to insufficient data collection
Solution Approach 1:
The patent implements feedback by continuously monitoring the quality of weight data collection and using this information to adjust the evaluation process. The system evaluates data completeness and signal quality in real-time, providing feedback to determine when sufficient data has been collected, thereby preventing premature or unnecessary rejections.
Solution Approach 2:
The patent applies preliminary action by collecting and pre-processing weight data before making the final weighing decision. The system performs preliminary signal filtering, noise reduction, and data validation steps before the object reaches the fixed evaluation point, ensuring that sufficient quality data is available for accurate weight determination.
Data Source
AI summary
Checkweigher system embodiments and associated weigh-in-motion methods that are usable to produce increased object weigh time and improved weight determination accuracy without a decrease in object throughput. Generally speaking, exemplary methods initiate weight data collection earlier than, and terminate weight data collection later than, known methods. An exemplary method may also make use of derived mean error data associated with object weight measurements at various locations along a checkweigher to determine if an object weight measured over less than a desired weigh time is nonetheless acceptable.